Highly reflective roofing system

ABSTRACT

A cool rooting system includes highly reflective calcined kaolin particles having a solar reflectance of 80% to 92%. When applied to a roofing substrate, the highly reflective kaolin particles produce a roofing system having a solar reflectance greater than or equal to 70%.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit under 35 U.S.C. §119 of U.S.Provisional Application No. 61/248,285, filed on Oct. 2, 2009, entitled“Highly Reflective Rooting System,” which is herein incorporated byreference in its entirety for all purposes.

TECHNICAL FIELD

The present invention relates to cool roofing systems. Moreparticularly, the present invention relates to a cool roofing systemincluding highly reflective particles that can be applied to a substrateto increase the solar reflectance of a roofing system to equal to orgreater than 70%.

BACKGROUND

Title 24 of the California Code of Regulations, and similar requirementsof other agencies, require the solar reflectance of commercial roofingmaterials to be a minimum of 70%. Many current roofing materials, suchas asphalt and modified bitumen, are black in color and have very lowsolar reflectance. Most of these black roofing materials use mineralgranules on the surface to reduce weathering and add fire resistance.Most current roofing granules for asphalt and other dark colored roofingmaterials are made from crushed rock such as feldspar, which are coatedwith a ceramic coating in order to make them white enough to achieve anacceptable solar reflectance. However, despite these efforts, thegranules that are commercially available today are not bright enough toincrease the solar reflectance of the black materials to meet the 70%standard.

SUMMARY

In sonic embodiments, the present invention is a cool roofing systemwhich includes at least one asphalt layer and at least one granularlayer including a plurality of highly reflective calcined kaolinparticles having a reflectance ranging from about 80% to about 92%adhered to the asphalt layer. The cool roofing system has a minimumsolar reflectance of 70% and, more particularly, a solar reflectanceranging from about 70% to about 82%.

According to various other embodiments, the present invention is a coolroofing system including a roofing substrate, at least one layer ofspray polyurethane foam applied to the roofing substrate such that ithas a thickness ranging from about one inch to about three inches, anelastomeric coating layer applied over and adhered to the spraypolyurethane foam layer, and a plurality of highly reflective, whitecalcined kaolin particles having a reflectance ranging from about 80% toabout 92% adhered to the elastomeric coating layer. The cool rootingsystem has minimum solar reflectance of 70% and, more particularly, asolar reflectance ranging from about 70% to about 82%.

While multiple embodiments are disclosed, still other embodiments of thepresent invention will become apparent to those skilled in the art fromthe following detailed description, which shows and describesillustrative embodiments of the invention. Accordingly, the drawings anddetailed description are to be regarded as illustrative in nature andnot restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a cool roofing system according to anembodiment of the present invention.

FIG. 2 is a schematic view of a cool roofing system according to anotherembodiment of the present invention.

DETAILED DESCRIPTION

Various materials have been investigated that may be used to make arooting granule or particle that when applied to a roofing substratemight achieve a highly reflective roofing surface. These variousmaterials include white quartz, tabular alumina, ceramic sand, andcalcined clay from a variety of sources globally. When applied to ablack roofing substrate, none of these materials were found to meet thedesired 70% solar reflectance standard. White quartz, for example,lacked the necessary opacity to provide sufficient protection to theroofing substrate from the sun's ultra-violet rays. Tabular alumina wasextensively tested for its reflectivity and other properties, but theresults were not satisfactory, Calcined clay from a variety of sourceswas investigated and was found not to produce a high enough solarreflectance when applied to a roofing substrate. Ceramic sand which ismade from pieces of white porcelain and ground into particles of thedesired size was also tested. Like the other materials that wereinvestigated, ceramic sand, when applied to an asphalt toolingsubstrate, also failed to meet the 70% solar reflectance standard.

Roofing materials and systems containing reflective particles andprocesses for making the same are generally shown and described in U.S.Pat. No. 7,291,358 and U.S. Published Application No. 2004/0017938, bothof which are incorporated herein by reference in their entirety for allpurposes.

A cool rooting system according to the various embodiments of thepresent invention includes highly reflective calcined kaolin particlesproducing a roofing system having a minimum solar reflectance of 70%.Calcined kaolin is known and referred to as kaolin chamotte, aluminumsilicate, calcined clay, calcined china clay, mullite and calcined flintclay. There are many different sources of calcined kaolin foundthroughout the world. Most calcined kaolin sourced from a variety oflocations is off-white, tan or light grey in color. However, there areEl few unique sources in the world where there are deposits of kaolinthat produce extremely bright white and highly reflective calcinedkaolin. These unique sources are found in China and in Central/EasternEurope.

The kaolin mined in China and Central/Eastern Europe is calcined attemperatures between 1100° C. and 1600° C. to improve the whiteness andhardness of the kaolin clay material. This unique kaolin clay is groundor crushed into granules having an approximate size ranging from 0.3 mmto 2.4 mm and its solar reflectance determined. The solar reflectance ofthese unique kaolin clay particles ranges from 80% to 92%. When appliedto a black roofing substrate at the rate normally used for rootingmaterials, the resultant reflectance was between 70% and 82%.

One example of highly reflective calcined kaolin that is suitable foruse in the various embodiments of the present invention isKaolinchamotte AS 45 obtained from Amberger Kaolinwerke located inHirschau and Schnaittenbach, Germany.

FIG. 1 is a schematic drawing of a cool roofing system 10 according toone embodiment of the present invention. The cool roofing system 10includes at least one asphalt layer 12 such as a layer of bitumen ormodified bitumen. Bitumen or modified bitumen can be composed of one ormore asphalt layers 14 and one or more layers of a reinforcing material16 such as, for example, polyester or fiberglass.

The upper asphalt layer 12 includes at least one granular layer 18including a plurality of highly reflective calcined kaolin particles 20adhered to or embedded within a top surface of the asphalt layer 12.According to various embodiments, the highly reflective calcined kaolinparticles have a solar reflectance ranging from about 80% to about 92%such that when applied to the reinforced asphalt layer 12 result in aroofing system having a minimum solar reflectance of 70% and, moreparticularly, a solar reflectance ranging from about 70% to about 82%.The particles 20 are bright white in color and have a size ranging fromabout 0.3 mm to about 2.4 mm. In one embodiment, the particles 62 are ofsubstantially the same particle size distribution. For example, theparticles 62 have a particle size distribution that corresponds to thefollowing:

Grade: (ASTM D451) U.S. Nominal % Retained Specification Sieve No.Opening Minimum Maximum 8 2.36 mm 0.0 0.1 12 1.70 mm 4.0 10.0 16 1.18 mm30.0 45.0 20 850 μm 25.0 35.0 30 600 μm 15.0 25.0 40 425 μm 2.09.0 >40 >425 μm 0.0 2.0 *Typical range

The cool rooting system 10 including the asphalt layer is produced bypassing a reinforcement material 16, such as fiberglass or polyester,through hot liquid asphalt, which impregnates and coats thereinforcement material 16. This coated strip is then run under a hopperwhich dispenses the calcined kaolin particles 20 onto the upper surfaceof the hot asphalt coated strip to substantially fully cover thesurface. This strip is then passed over a roller or drum to flatten theparticles 20 and press them into the asphalt included in the reinforcedasphalt layer 12. The roofing material can be provided in the form ofindividual shingles or sheets which can then be applied to anycommercial, industrial low or steep slope roofing surface.

FIG. 2 is a schematic drawing of a cool roofing system 50 according toanother embodiment of the present invention. The cool roofing system 50shown in FIG. 2 includes at least one layer or spray polyurethane foam52 applied to a roofing substrate 54. The roofing substrate 54 can be anexposed rooting surface of a structure or sheets or layers of a roofingmaterial. For example, in one embodiment, the layer of spraypolyurethane foam 52 can be applied directly onto a roofing surface of abuilding. In other embodiments, the spray polyurethane foam layer 52 canhe applied to a variety of surfaces including concrete, wood, gravel,asphalt, built-up rooting (BUR), modified bitumen, single ply membranesand the like. In one embodiment, the spray polyurethane foam layer 52can be applied over another spray polyurethane foam layer. A thicknessof the spray polyurethane foam layer typically ranges from about 1 inchto about 3 inches.

Additionally, the cool roofing system 50 depicted in FIG. 2 includes atleast one layer of an elastomeric coating 56. The elastomeric coating 56is applied to the upper surface 58 of the spray polyurethane foam layer52 within 24 hours to protect the spray polyurethane foam from UV lightdamage. In one embodiment, the elastomeric coating 56 is applied to theupper surface of the spray polyurethane foam layer 52 such that itsubstantially coats the entire surface of the spray polyurethane foamlayer 52. The elastomeric coating can be formed from a wide variety ofelastomeric materials including, but not limited to acrylics, urethanes,and silicones.

The cool rooting system 50 also includes at least one granular layer 60.The granular layer 60 includes a plurality of highly reflective calcinedkaolin particles 62, such as those described above, adhered to orembedded within the elastomeric coating layer 56. The panicles 62 arewhite in color and can range in size from about 0.3 mm to about 2.4 mm.In one embodiment, the particles 62 are of substantially the same size.Additionally, the highly reflective calcined kaolin particles have asolar reflectance ranging from about 80% to about 92% that when appliedto the reinforced asphalt layer 12 results in a roofing system having atminimum solar reflectance of 70% and, more particularly, ranging fromabout 70% to about 82%.

In one embodiment, the cool rooting system 50 is produced by applying atleast one layer of spray polyurethane foam to a rooting substrate suchas a roof surface, and then coating the spray polyurethane foam layerwith an elastomeric coating layer. While elastomeric coating layer isstill wet, calcined kaolin granules are then applied to the coating.

In some embodiments, the calcined kaolin particles used in the roofingsystems, as described above, can include a coating and/or a surfacetreatment. The calcined kaolin particles can be coated and/or theirsurfaces treated for any number of reasons including dust control, toenhance and/or increase water repellency and to prevent various kinds ofstaining.

Various compounds can be used to coat or treat the surface the calcinedkaolin particles described above according to the various embodiments ofthe present invention. These compounds include, but are not limited tothe following: silanes, siloxanes, polysiloxanes, organo-siloxanes,silicates, organic silicates, silicone resins, acrylics, urethanes,polyurethanes, glycol ethers and mineral oil. Table 1 provides a list ofexemplary commercially available coatings and surface treatments andtheir general descriptions that can be used to coat or treat the surfaceof calcined kaolin particles or other roofing particles. Additional,exemplary coatings, surface treatments, and methods of coating andtreating particles are shown and described in U.S. Pat. No. 7,241,500,U.S. Pat. No. 3,479,201, U.S. Pat. No. 3,255,031, and U.S. Pat. No.3,208,571, all of which are incorporated herein by reference in theirentirety for all purposes.

TABLE 1 Coating/Surface Treatment Description Manufacturer Salt WaterDeionized water, alkylalkoxysilanes, DuPont Resistant siloxanes,alcohol, ethoxylate Sealer* Maximum Bullet Deionized water, mixedfluoroalkyl DuPont Proof Sealer* salts, propylene glycol monobutyl etherHeavy Duty Deionized water mixed fluoroalkyl DuPont Sealer* salts,propylene glycol, monobutyl ether Heavy Duty Aliphatic hydrocarbons,proprietary DuPont Exterior silicone resin, alkyl alkoxysilane, Sealer*methanol Impregnator Aliphatic hydrocarbons, butyl DuPont Pro* acetate,fluorinated acrylic copolymer, fragrance Rich Color Aliphatichydrocarbons, proprietary DuPont Enhancer silicone resin, alkylalkoxysilane, Pro* methanol, butyl acetate AcryShield ® Proprietaryacrylic formulation National A130 Coatings Corporation AcryShield ®Proprietary acrylic formulation National A179-X628 Coatings CorporationQW77 Urethane Henkel Corporation Water-based Polyurethane Minwaxpolyurethanes Corporation Sitren ® 595 Polydimethylsiloxane emulsionEvonik Corporation Sitren ® 270 Aqueous emulsion based on reactiveEvonik organo-siloxanes Corporation SILRES ® Water-thinable, solventlessemulsion Wacker BS1011A based on a mixture of silane and Chemie AGsiloxane SILRES ® Water-thinable, solventless emulsion Wacker BS3003based on a mixture of silane and Chemie AG siloxane Tego XP 5000Emulsion of silicone resins Evonik Goldschmidt Corporation Kynar RC-10,Acrylic copolymer, vinylidine Arkema Inc. 147 fluoride copolymerRHOPLEX ™ 100% acrylic polymer The Dow EC 2540 Chemical Company Sycoat235 Acrylic copolymer emulsion Saiden Technologies *Marketed under theStoneTech ® Professional brand

To maintain the high solar reflectance oldie calcined kaolin particles,the coating and/or surface treatment should be applied to the calcinedkaolin particles such that the coating and/or surface treatment does notsignificantly decrease the reflectance of the calcined kaolin particles.For example, many of the coatings and/or surface treatments are sealantsor otherwise clear coatings that do not adversely affect the overallsolar reflectance of the calcined kaolin particles. In one embodiment,the calcined kaolin particles are treated with an emulsion of silanesand siloxanes without added solvents. In another embodiment, thecalcined kaolin particles are treated with SILRES BS3003.

The surface treatments and/or coatings can be applied to calcined kaolinparticles using a variety of methods and processes known to those ofskill in the art. For example, in one exemplary embodiment, after theraw material has been crushed and sized according to the preferredscreen size and packaged, the particles can be treated by adding theparticles to an aqueous solution fully saturating the particles with thetreatment and then, immediately drying the particles to drive off excessmoisture at a temperature not exceeding 600° F. In another exemplaryembodiment, after the raw material has been crushed and sized accordingto the preferred screen size and packaged, the panicles can be posttreated by spraying the particles with an aqueous solution and thenimmediately drying the particles to drive off excess moisture at atemperature not to exceed 600° F. In yet another exemplary embodiment,after the raw material has been crushed and sized according to thepreferred screen size, the particles can be treated by spraying thepanicles with an aqueous solution and then immediately kiln drying theparticles to drive off excess moisture at a temperature not to exceed600° F. after which time they can be packaged. In still yet anotherembodiment of coating and/or treating the surface of calcined kaolinparticles, after the raw material has been crushed and sized accordingto the preferred screen size, the particles are treated by spraying withan aqueous solution followed by immediately aerating the particles todrive off excess moisture after which time the particles can bepackaged. The coatings and/or surface treatments may be applied asdelivered (e.g., off the shelf) or from aqueous dilutions. The dilutionratio may range from 1:5 to 1:200. The dilutions may be prepared fromdemineralized water.

EXAMPLES Example 1

Treated Granule Preparation

The method of sample preparation for laboratory testing was as follows.A small plastic or glass container was placed on a digital scale, andthe scale zeroed. Approximately 1 oz. (approximately 29.5 ml or 35grams) of the treatment solution to be tested was placed into thecontainer. The scale was then re-zeroed. 100 grams of calcined kaolinrooting granules was added to the container. The container was thenclosed with a lid. The container containing the calcined kaolin roofinggranules and the treatment solution was vigorously agitated to ensurecomplete coverage of the granules by the treatment. Next, the treatedgranules wore removed and evenly spread out on a foil tray. The traycontaining the treated granules was placed into an oven preheated to 80°C. and the treated granules were dried overnight. The treated granuleswere removed from the oven and allowed to cool for several hours. Theobjective of cooling the treated granules was to ensure that thegranules return to an ambient or equalized humidity as they might befound prior to a production run of the product.

A brief description of each of the different granules and treatmentsappear in Table 2 below.

TABLE 2 Description Manufacturer Granule #1 WA-14 calcined kaolinparticle Sedlecky Kaolin having a reflectivity ranging (Bo{hacek over(z)}i{hacek over (c)}any, Czech from 70 to 92%. Republic) Granule #2WA-11 calcined kaolin particle AKW (Hirschau, having a reflectivityranging Germany) from 70 to 92%. Treatment #1 SITREN 595 EvonikIndustries AG (Essen, Germany) Treatment #2 TEGO XP 5000 EvonikIndustries AG (Essen, Germany) Treatment #3 SILRES BS1001A Wacker ChemieAG (Munich, Germany) Treatment #4 SILRES BS3003 Wacker Chemie AG(Munich, Germany)

Example 2

Reflectivity

Reflectivity of each or the treated samples was measured using a D&SReflectometer, Model SSR-ER Version 6 (Devices and Services Company,Dallas, Tex.). To carry out the measurement using the reflectometer,about 100 g of treated sample was placed onto a sample receiving dish.The sample was smoothed out such that the surface of the sample in thedish was roughly level. The reflectometer was cycled through eachmeasurement cycle 1-2 times for each measurement location. A total offive measurements locations were used. The measurement locationsrepresented the four points on a compass (north, south, east and west),with the fifth measurement taken at the center of the sample dish. Thereflectivity readings at each of the five measurement locations wereaveraged together to obtain an average reflectivity for each individualtreated sample. The average reflectivities of each of the treatedsamples are presented in Table 3 below.

TABLE 3 Sample Reflectivity Granule #1, Treatment #1 82.3% Granule #1,Treatment #2 82.5% Granule #1, Treatment #3 82.5% Granule #1, Treatment#4 82.4% Granule #1, Untreated 83.9% Granule #2, Treatment #1 82.5%Granule #2, Treatment #2 83.2% Granule #2, Treatment #3 83.4% Granule#2, Treatment #4 83.7% Granule #2, Untreated 83.7%

Example 3

Water Repellency Test

The water repellency is a quality control test frequently used in theroofing granule industry. It is important to have hydrophobic roofinggranules because hydrophilic granules may exhibit difficulty in beingadhered to an asphalt-based substrate. When roofing granules are appliedto an asphalt-based substrate, water may then be sprayed on the hotasphalt to cool the heated substrate. If the rooting granules arehydrophilic, water may be present between the granules and thesubstrate, thereby hindering granule adherence to the asphalt-basedsubstrate.

Each of the granules used in the water repellency test was treated witha solution according to the method described above such that the weightof the treatment solution to the weight of the granules was 2% byweight. Products treated with SILRES BS3003 were treated using a 0.67%dilution. The 0.67% dilution was prepared by weighing 45 g of deionizedwater into a container and into the same container, weighing 2.50 g ofSILRES BS3003. The mixture was gently swirled to form a dilutedemulsion. The diluted SILRES BS3003 was then applied to the granules. Abrief description of each of the samples is provided in Table 4 below.

TABLE 4 Sample Coating and/or Treatment Granule a SITREN 595 WA-11 bTEGO XP 5000 WA-11 c SYCOAT 235 WA-11 d SILRES BS 1001A WA-11 eACRYSHIELD A130 WA-11 f ACRYSHIELD A179-X628 WA-11 g EC 2540 WA-11 hKYNAR R-10 147 WA-11 i SITREN 595 WA-14 j TEGO XP 5000 WA-14 k SILRESBS1001A WA-14 l SILRES BS3003 WA-14 m SILRES BS3003 WA-11

WA-11 is a calcined kaolin granule supplied by AKW of Hirschgau,Germany, The reflectivity of WA-11 ranges from about 80% to 92%. WA-14is a calcined kaolin particle supplied by Sedlecky Kaolin of Bo{hacekover (z)}i{hacek over (e)}any, Czech Republic. The reflectivity of WA-14ranges from about 80% to 92%.

Water repellency was measured by placing three drops of distilled waterfrom an eye dropper onto a 25 gram pile of treated roofing granules. Thedrops were placed in a depression that had been made in the center ofthe pile of granules. The three drops of distilled water formed a beadin the depression. A measurement was taken for the amount time it takesfor the head to break up and sink down through the granules. Longertimes indicate better hydrophobicity. The water repellency test resultsfor each of the treated samples are presented in Table 5 below.

TABLE 5 Time to Water Sample Absorption a >120 min b >120 min c <1 mind >120 min e <1 min f <45 min g <10 min h <1 min i >120 min j >120 mink >120 min l >120 min m >120 min

The samples treated with SITREN 595, TEGO XP 5000 and SILRES BS 1001Ashowed more favorable water repellency test results. The sample treatedwith SILRES BS3003 produced superior results.

Example 4

4-Day Stain Test

The 4-Day Stain Test is another quality control test frequently used inthe roofing granule industry. The 4-Day Stain Test is an acceleratedmeasurement of the tendency or roofing granules to adsorb asphaltic oilsin an asphalt-based substrate. Each of the granules used in the 4-DayStain test was treated with a solution according to the method describedabove such that the weight of the solution to the weight of the granuleswas 2% by weight. A brief description of each the different granules,treatments and asphalt types used to create each of the samples usedevaluated using the 4-Day Stain Test is provided in Table 6 below.

TABLE 6 Description Manufacturer Granule #1 WA-14 calcined kaolinparticle Sedlecky Kaolin having a reflectivity ranging (Bo{hacek over(z)}i{hacek over (c)}any, Czech from about 80 to 92%. Republic) Granule#2 WA-11 calcined kaolin particle AKW (Hirschau, having a reflectivityranging Germany) from about 80 to 92%. Asphalt #1 Type AC-7 asphalthaving low Marathon Petroleum melting point. Company LLC (Findlay OH)Asphalt #2 Type III roofing asphalt. This United Asphalts type ofasphalt is typically (Commerce City, CO) used in the “hot mop” built uptype of roofing. Treatment #1 SITREN 595 Evonik Industries AG (Essen,Germany) Treatment #2 TEGO XP 5000 Evonik Industries AG (Essen, Germany)Treatment #3 SILRES BS1001A Wacker Chemie AG (Munich, Germany) Treatment#4 SILRES BS3003 Wacker Chemie AG (Munich, Germany)

The treated granules for each sample were embedded in asphalt that hadbeen heated to about 200° C. The embedded treated granules were thenplaced on a tray in an oven at 85° C. for 96 hours (4 days). The trayswere removed from the oven, and the asphalt including the embeddedgranules was allowed to cool to room temperature. The granules were thenevaluated for staining using an 8× magnifier/loupe. The stain valueswere evaluated on a pass/no pass basis and then ranked according torelative staining. The 4-Day Stain Test results are provided in Table 7below.

TABLE 7 Sample Description Pass/Fail A1 Granule #1, Treatment #1,Asphalt #1 F A2 Granule #1, Treatment #1, Asphalt #2 P B1 Granule #2,Treatment #1, Asphalt #1 F B2 Granule #2, Treatment #1, Asphalt #2 P C1Granule #1, Treatment #2, Asphalt #1 F C2 Granule #1, Treatment #2,Asphalt #2 F D1 Granule #2, Treatment #2, Asphalt #1 F D2 Granule #2,Treatment #2, Asphalt #2 P E1 Granule #1, Treatment #3, Asphalt #1 F E2Granule #1, Treatment #3, Asphalt #2 P F1 Granule #2, Treatment #3,Asphalt #1 F F2 Granule #2, Treatment #3, Asphalt #2 P G1 Granule#1,Untreated, Asphalt #1 F G2 Granule#1, Untreated, Asphalt #2 F H1Granule#2, Untreated, Asphalt #1 F H2 Granule#2, Untreated, Asphalt #2 FI1 Granule #1, Treatment #4, Asphalt #1 F I2 Granule #1, Treatment #4,Asphalt #2 P J1 Granule #2, Treatment #4, Asphalt #1 F J2 Granule #2,Treatment #4, Asphalt #2 P

The samples treated with SITREN 595, SILRES BS1001A and SILRES BS3003showed the most favorable test results. In particular, the samplestreated with SILRES BS3003 showed significantly less staining.

Example 5

Adhesion Test

The pick test is a practical test used in the roofing granule industryto predict the adhesive characteristics of roofing granules towardasphalt.

Preparation (Screening) of Particles

The standard #11 particle distribution is what was used in the followingsteps.

Preparation of Asphalt

Asphalt is heated to about 200° C. The fluid asphalt in poured into analuminum tray so that the entire surface is just coated. This requiresabout 5 grams of asphalt per sample.

Pick Test

The asphalt is reheated on a small hotplate to about 200° C. until theasphalt becomes molten. About 25 grams of granules are broadcast acrossthe entire surface until the entire asphalt surface has been covered.While the asphalt is still warm, the granules are pressed into theasphalt, as they would be in a production environment. Due to the rapidcooling that can take place the samples are placed into an 80° C. ovenfor 4 days after which time they are allowed to completely cool toroom/ambient temperature.

The particles are picked out of the cooled asphalt. Only those particleswhich were embedded well are examined. A picked particle is examinedwith an 8× magnifier/loupe to estimate the amount of asphalt that wasadhered to it. The granules adhesion was measured on two differentelements. The first was whether the adhesion Failure was due to anadhesive or cohesive failure of the asphalt. The second clement was aranked judgment of the adhesive strength, Best/Average/Poor. The Bestrank required a concerted effort to remove granules. The Average rankwould be compared to most current market granulated products granuleadhesion. The Poor rank was the evidence of little effort required todislodge the granule. The results of the pick test are presented inTable 8.

TABLE 8 Adhesive/ 1 = BEST, Cohesive 2 = AVG, Treatment .67%-2% byweight Sample Failure 3 = POOR Granule #1, Treatment #1, Asphalt #1 A1 A3 Granule #1, Treatment #1, Asphalt #2 A2 C 1, 2 Granule #2, Treatment#1, Asphalt #1 B1 A 3 Granule #2, Treatment #1, Asphalt #2 B2 A/C 2Granule #1, Treatment #2, Asphalt #1 C1 A/C 2 Granule #1, Treatment #2,Asphalt #2 C2 A/C 1 Granule #2, Treatment #2, Asphalt #1 D1 A 3 Granule#2, Treatment #2, Asphalt #2 D2 C 1 Granule #1, Treatment #3, Asphalt #1E1 A/C 3 Granule #1, Treatment #3, Asphalt #2 E2 C 1, 2 Granule #2,Treatment #3, Asphalt #1 F1 C 1 Granule #2, Treatment #3, Asphalt #2 F2A 3 Granule#1, Untreated, Asphalt #1 G1 C 2 Granule#1, Untreated,Asphalt #2 G2 A 3 Granule#2, Untreated, Asphalt #1 H1 A/C 1, 2Granule#2, Untreated, Asphalt #2 H2 A/C 3 Granule#1, Treatment #4,Asphalt #1 I1 C 1 Granule#1, Treatment #4, Asphalt #2 I2 C 1 Granule#2,Treatment #4, Asphalt #1 J1 A/C 1 Granule#2, Treatment #4, Asphalt #2 J2C 1

Various modifications and additions can be made to the exemplaryembodiments discussed without departing from the scope of the presentinvention. For example, while the embodiments described above refer toparticular features, the scope of this invention also includesembodiments having different combinations of features and embodimentsthat do not include all of the above described features.

What is claimed is:
 1. A cool roofing system comprising: at least oneasphalt layer and at least one granular layer comprising a plurality ofhighly reflective calcined kaolin particles having a reflectance rangingfrom about 30% to about 92% adhered to the asphalt layer, wherein thecool roofing system has minimum solar reflectance of 70% or more.
 2. Thecool roofing system according to claim 1, wherein the solar reflectanceof the cool roofing system ranges from about 70% to about 82%.
 3. Thecool roofing system according to claim 1, wherein the calcined kaolinparticles have a particle size ranging from about 0.3 mm to about 2.4mm.
 4. The cool roofing system according to claim 1, wherein thecalcined kaolin particles further comprise a surface treatment.
 5. Thecool roofing system according to claim 4, wherein the surface treatmentis a surface treatment selected from the group consisting of silanes,siloxanes, polysiloximes, organo-siloxanes, silicates, organicsilicates, silicone resins, acrylics, urethanes, polyurethanes, glycolethers and mixtures thereof.
 6. The cool roofing system according toclaim 4, wherein the treatment comprises a solventless emulsioncomprising silanes and siloxanes.
 7. The cool roofing system accordingto claim 1, further comprising a surface treatment applied to thegranular layer.
 8. The cool roofing system according to claim 7, whereinthe surface treatment comprises a surface treatment selected front thegroup consisting of silanes, siloxanes, polysiloxanes, organo-siloxanes,silicates, organic silicates, silicone resins, acrylics, urethanes,polyurethanes, glycol ethers and mixtures thereof.
 9. The cool roofingsystem according to claim 7, wherein the surface treatment composes anemulsion comprising silanes and siloxanes.
 10. A cool roofing systemcomprising: a roofing substrate, at least one layer of spraypolyurethane loam applied to the roofing substrate, an elastomericcoating layer applied over and adhered to the spray polyurethane foamlayer, and a granular layer comprising plurality of highly reflectivecalcined kaolin particles having a reflectance ranging from about 80% toabout 92% adhered to a top surface of the elastomeric coating layer,wherein the cool roofing system has a minimum reflectance of at least70%.
 11. The cool roofing system according to claim 10, wherein athickness of the spray polyurethane foam layer ranges from about 1 inchto about 3 inches.
 12. The cool roofing system according to claim 10,wherein the solar reflectance ranges from at least 70% to about 84%. 13.The cool roofing system according to claim 10, wherein the calcinedkaolin particles have a particle size ranging from about 0.3 mm to about2.4 mm.
 14. The cool roofing system according to claim 10, wherein theelastomeric coating layer comprises any one of an acrylic, urethane orsilicone.
 15. The cool roofing system according to claim 10, wherein thecalcined kaolin particles further comprise a surface treatment.
 16. Thecool roofing system according to claim 15, wherein the surface treatmentis a treatment selected from the group consisting of silanes, siloxanes,polysiloxanes, organo-siloxanes, silicates, organic silicates, siliconeresins, acrylics, urethanes, polyurethanes, glycol ethers and mixturesthereof.
 7. The cool rooting system according to claim 16, wherein thesurface treatment comprises an emulsion of silanes and siloxanes. 18.The cool rooting system according to claim 10, further comprising asurface treatment applied to the granular layer.
 19. The cool roofingsystem according to claim 18, wherein the surface treatment comprises anemulsion of silanes and siloxanes.
 20. The cool roofing system accordingto claim 18, wherein the surface treatment comprises a surface treatmentselected from the group consisting of silanes, siloxanes, polysiloxanes,organo-siloxanes, silicates, organic silicates, silicone resins,acrylics, urethanes, polyurethanes, glycol ethers and mixtures thereof.